Modified pier for modular, portable, interlocking system

ABSTRACT

A pier for a modular, portable, interlocking decking system, the pier having a generally planar plate with a bottom surface and a top surface and a plurality of receiver blocks extending from the top surface of the plate. Each receiver block has a generally dome-shaped load-bearing surface. A plurality of piers is used in a decking system along with at least one surface pad, the surface pad having a generally planar, horizontal upper surface, and a lower portion including a plurality of block receptacles. The bottom surface of the plate of each structural pier rests upon a supporting surface, and the block receptacles of the surface pad each engage the generally dome-shaped load-bearing surface of a corresponding structural pier.

This application claims priority to U.S. Provisional Patent Application 61/734,056, filed on Dec. 6, 2012, and entitled MODIFIED PIER FOR MODULAR, PORTABLE, INTERLOCKING DECKING SYSTEM, the entire contents of which is incorporated by reference herein.

TECHNICAL FIELD

The present invention relates to patio, decking, platform, walkway, and/or stage systems which incorporate non-traditional construction methods, typically used in the assembly of traditional pressure treated decks, composite decks, cement or stone patio pavers and any surface constructed to enhance outdoor and/or indoor living needs and use. The present invention particularly is a modified pier for use with a modular, portable and interlocking decking system that is predominately and ideally comprised of post-consumer and/or industrial thermo-plastic waste that can easily be assembled, disassembled, stored, or transported for relocation or reconfiguration.

BACKGROUND OF THE INVENTION

In accordance with the disclosure of U.S. Pat. No. 8,011,148 (the '148 patent), the entirety of which is incorporated by reference herein, the present invention is a modification of the structural support pier described in the '148 patent, with improved performance characteristics. Though not specifically mentioned in the detailed description below, it is understood that the pier design and pier extension systems disclosed herein may be fully incorporated into the system of the '148 patent to the extent that they are compatible, as will be appreciated by one skilled in the art.

SUMMARY

In one aspect, a pier for a modular, portable, interlocking decking system is disclosed. The pier has a generally planar plate having a bottom surface and a top surface and a plurality of receiver blocks extending from the top surface of the plate. Each receiver block has a generally dome-shaped load-bearing surface.

In another aspect a modular, portable, interlocking decking system is disclosed. The system includes a plurality of structural piers, each structural pier including a generally planar plate having a bottom surface and a top surface and a plurality of receiver blocks extending from the top surface of the plate of each structural pier. Each receiver block has a generally dome-shaped load-bearing surface. The system further includes at least one surface pad, the surface pad having a generally planar, horizontal upper surface, and a lower portion including a plurality of block receptacles. The bottom surface of the plate of each structural pier rests upon a supporting surface, and the block receptacles of the surface pad each engage the generally dome-shaped load-bearing surface of a corresponding structural pier.

Other aspects of the disclosed pier and decking system will become apparent from the following description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top isometric view of a support pier according to an embodiment of the invention;

FIG. 2 is a bottom isometric view of a support pier according to an embodiment of the invention;

FIG. 3 is a top isometric view of a surface pad according to an embodiment of the invention;

FIG. 4 is a bottom isometric view of a surface pad according to an embodiment of the invention;

FIG. 5 is a top isometric view of a riser aligned with a structural pier;

FIG. 6 is a top isometric view of a riser engaging a structural pier;

FIG. 7 is a top isometric view of a pair of risers aligned with a structural pier;

FIG. 8 is a top isometric view of a pair of risers engaging a structural pier;

FIG. 9 is a top isometric view of a shim aligned with a structural pier;

FIG. 10 is a top isometric view of a shim engaging a structural pier;

FIG. 11 is a top isometric view of a pair of shims aligned with a structural pier; and

FIG. 12 is a top isometric view of a pair of shims engaging a structural pier;

DETAILED DESCRIPTION

Referring now to the drawings, FIG. 1 and FIG. 2 depict an embodiment of a structural pier 10. Structural pier 10 has a plate 11 with a top surface 12 and a bottom surface 14. A plurality of receiver blocks 16, each topped by a generally dome-shaped load-bearing surface 18, extend upward from the top surface 12 of the pier 10. The dome shape of the load-bearing surfaces 18 enhances the load-bearing characteristics of pier 10 by providing improved weight distribution capabilities, described in more detail below.

In one embodiment, each structural pier 10 may have four receiver blocks 16. Receiver blocks 16 may preferably be of hollow construction, as best seen in FIG. 2, resulting in hollow cavities 13 on the underside of pier 10. Structural supports 20, 22, 26 may extend from top surface 12 to link receiver blocks 16 together and to enhance system stability both across pier 10 itself and also with respect to engagement between pier 10 and other system components to be described below, as well as other system components not specifically mentioned below but nonetheless incorporated by reference through the '148 patent.

Pier 10 may also incorporate other features as described in the analogous pier component of the '148 patent. For instance, pier 10 may include cam slot 28 to facilitate incorporation of a cam lock fastener system as disclosed in the '148 patent. Plate 11 of pier 10 may further incorporate holes 30 to allow securement or anchoring of pier 10 to a supporting surface or substructure using a fastener and anchor bolt system (not shown) as disclosed in the '148 patent. To provide still further anchoring capability, plate 11 may further include thru-hole 32 located preferably at the center of plate 11. Thru-hole 32 may be larger in diameter than holes 30, and may preferably be approximately one inch in diameter, or any other diameter suitable for the specific application, as will be appreciated by one skilled in the art.

FIG. 3 and FIG. 4 illustrate an embodiment of surface pad 50. Surface pad 50 aligns and engages with pier 10. Surface pad 50 has a generally planar, horizontal, upper pad surface 52, and a lower portion 54 containing a plurality of block receptacles 56. In one embodiment, surface pad 50 is rectangular in shape and block receptacles 56 are located at each corner. Upper pad surface 52 may have weep holes on channels 58 arranged in any one of a variety of patterns known to one of skill in the art to provide drainage by distributing water away from the system. Surface pad 50 also has holes 60 with molded shoulders 62 for use with a cam system as described in the '148 patent.

Lower portion 54 of surface pad 50 may be generally hollow and contain structural ribs 64 arranged to distribute dead and live surface loads as known to one skilled in the art. Block receptacle 56 is configured to engage load-bearing surface 18 of structural pier 10 when pad 50 is positioned on top of pier 10. Ribs 66 are positioned within block receptacle 56 to interface and engage with load bearing surface 18 to transfer a load from surface pad 50 to load bearing surface 18 of pier 10. Ribs 66 are shaped to conform with the generally dome-shaped surface of load bearing surface 18, thereby facilitating uniform engagement between block receptacle 56 and load bearing surface 18. Ribs 66 may be molded into the body of surface pad 50. In one embodiment, eight ribs are used, but four, six, sixteen, or any other quantity of ribs 66 sufficient to effectively transfer a load from surface pad 50 to pier 10 may be used. Other features of the analogous surface pad component disclosed in the '148 patent may be further incorporated into surface pad 50 as presently described.

The benefits of the dome-shaped load-bearing surface 18 are especially apparent when a modular, portable, interlocking decking system incorporating structural pier 10 is used on surface with an uneven grade. The disclosed structural pier 10 provides separate load-bearing surfaces 18 for each receiver block 16. Consequently, when multiple surface pads 50 are positioned to interface and engage with a single structural pier 10, each surface pad 50 is independently supported on top of its own designated load-bearing surface 18. Further, the dome shape of the load-bearing surface 18 allows generally even weight distribution across load-bearing surface 18 even if block receptacle 56 of surface pad 50 is not precisely aligned with receiver block 16. As a result, if pier 10 is situated on grade such that all surface pads 50 engaged with pier 10 are not precisely coplanar, the combination of independent load-bearing surfaces and their dome shape provides a durable, adaptable system to shoulder uneven load configurations, thereby making the modified pier 10 adaptable for use on a wide variety of surfaces.

Referring now to FIGS. 5-8, an embodiment of a pier extension system is disclosed for use when it is desirable to raise the height of pier 10 a distance from a support surface. For instance, a pier extension would be required to install a flat-surfaced deck system over a sloped grade, or alternatively to create a stepped platform over a flat surface. One skilled in the art will appreciate other scenarios where height modification of pier 10 may be desirable.

Riser 80 is positioned below pier 10, as seen in FIG. 5. Riser 80 includes side panels 82, pier-engagement surface 84, outer lip 86, and structural ribs 88. Side panels 82 form a perimeter shape of riser 80 approximately identical to that of pier 10. Side panels 82 may be of any height suitable for the intended use of one skilled in the art, including two, four, or six inches, but may preferably be three inches in height. As seen in FIG. 6, pier 10 engages riser 80 by resting upon pier-engagement surface 84, which is the top surface of the system of structural ribs 88. Outer lip 86 extends upward from pier-engagement surface 84 to a height approximately equal to the thickness of plate 11 of pier 10. Outer lip 86 prevents pier 10 from horizontal sliding off of pier-engagement surface 84 once pier 10 is in place. Riser 80 may preferably include thru-hole 89, which is positioned and sized for vertical alignment with corresponding thru-hole 32 of pier 10, to facilitate simultaneous anchoring of both riser 80 and pier 10, further enhancing the stability of the system.

As illustrated in FIG. 7 and FIG. 8, two or more risers 80, 80′ may be stacked to further extend the functional height of pier 10. In such a configuration, pier 10 rests upon riser 80 as indicated above, but side panels 82 of riser 80 rest upon pier-engagement surface 84′, and lip 86′ stabilizes riser 80 upon riser 80′ against horizontal movement. Further, thru-holes 89, 89′ of risers 80, 80′ may preferably both be positioned and sized for vertical alignment with each and other and also with thru-hole 32 of pier 10 to facilitate anchoring and provide further stability to the system. One skilled in the art will appreciate that unlimited extension may be achieved through stacking multiple risers 80, 80′.

Referring now to FIGS. 9-12, a second embodiment of a pier extension system is disclosed. Shim 90 is positioned below pier 10, as seen in FIG. 9. Shim 90 includes side panels 92, pier-engagement surface 94, structural ribs 96, and stabilizers 98. Side panels 92 form a perimeter shape of shim 90 approximately identical to that of pier 10. Side panels 92 may be of any height suitable for the intended use of one skilled in the art, including one-half, two, four, or six inches, but may preferably be one inch in height. As seen in FIG. 10, pier 10 engages shim 90 by resting upon pier-engagement surface 94, which is the top surface of the system of structural ribs 96. Stabilizers 98 extend upward from pier-engagement surface 94 at locations that coincide with the location of receiver blocks 16 of pier 10, such that when pier 10 is engaged with shim 90, stabilizers 98 enter hollow cavities 13 to form a peg and hole system. Stabilizers 98 thereby prevent pier 10 from sliding horizontally off pier-engagement surface 94 by pinning pier 10 in place. Shim 90 may preferably include thru-hole 99, which is positioned and sized for vertical alignment with corresponding thru-hole 32 of pier 10, to facilitate simultaneous anchoring of both shim 90 and pier 10, further enhancing the stability of the system.

As illustrated in FIG. 11 and FIG. 12, two or more shims 90, 90′ may be stacked to further extend the functional height of pier 10. In such a configuration, pier 10 rests upon shim 90 as indicated above, and side panels 92 of shim 90 rest upon pier-engagement surface 94′ of shim 90′. Stabilizers 98′ prevent horizontal sliding of shim 90 off of shim 90′ via hollow cavities (not shown) on the underside of stabilizers 98 of shim 90 that are analogous to hollow cavities 13 of pier 10. Further, thru-holes 99, 99′ of shims 90, 90′ may preferably both be positioned and sized for vertical alignment with each and other and also with thru-hole 32 of pier 10 to facilitate anchoring and provide further stability to the system. One skilled in the art will appreciate that unlimited extension may be achieved through stacking multiple shims 90, 90′. One skilled in the art will also appreciate that the disclosed embodiments of riser 80 and shim 90 may be used in conjunction with each other such that shim 90 may rest upon riser 80 to achieve a specific desired pier height. In such a configuration, thru-hole 99 of shim 90, thru-hole 89 of riser 80, and thru-hole 32 of pier 10 are preferably all positioned in vertical alignment with each other. 

What is claimed is:
 1. A pier for a modular, portable, interlocking decking system comprising: a generally planar plate having a bottom surface and a top surface; and a plurality of receiver blocks extending from the top surface of the plate; wherein each receiver block has a generally dome-shaped load-bearing surface.
 2. The pier of claim 1, further comprising a structural support between a first of the plurality of receiver blocks and a second of the plurality of receiver blocks, wherein the structural support links the first of the plurality of receiver blocks to the second of the plurality of receiver blocks.
 3. The pier of claim 2, wherein the structural support extends from the top surface of the plate.
 4. The pier of claim 1, further comprising a structural support extending from the top surface of the plate to one of the plurality of receiver blocks.
 5. The pier of claim 1, wherein the dome-shaped load-bearing surface includes a slot therethrough.
 6. The pier of claim 1, wherein the plate includes a thru-hole extending entirely therethrough approximately at the center thereof.
 7. The pier of claim 1, wherein the plurality of receiver blocks are located proximate the outer perimeter of the plate.
 8. The pier of claim 1, comprising four receiver blocks.
 9. A modular, portable, interlocking decking system comprising: a plurality of structural piers, each structural pier including a generally planar plate having a bottom surface and a top surface; a plurality of receiver blocks extending from the top surface of the plate of each structural pier, wherein each receiver block has a generally dome-shaped load-bearing surface; at least one surface pad, the surface pad comprising a generally planar, horizontal upper surface, and a lower portion including a plurality of block receptacles; wherein the bottom surface of the plate of each structural pier rests upon a supporting surface, and the block receptacles of the surface pad each engage the generally dome-shaped load-bearing surface of a corresponding structural pier.
 10. The decking system of claim 9, wherein the surface pad is rectangular in shape.
 11. The decking system of claim 9, wherein the block receptacles include a plurality of structural ribs therein, the plurality of structural ribs shaped to interface and engage with the generally dome-shaped load-bearing surface of the receiver block of the structural pier.
 12. The decking system of claim 9, further comprising a riser with a pier-engagement surface, wherein the pier-engagement surface of the riser receives one of the plurality of structural piers thereon.
 13. The decking system of claim 12, wherein the riser further comprises a lip extending from the pier-engagement surface, wherein the lip prevents the structural pier received on the riser from sliding off of the pier-engagement surface of the riser.
 14. The decking system of claim 12, wherein the riser is a first riser, and wherein the decking system further comprises a second riser, wherein the second riser receives the first riser thereon.
 15. The decking system of claim 12, wherein the riser further comprises a plurality of structural ribs therein.
 16. The decking system of claim 9, wherein the receiver blocks of the structural piers define hollow cavities on the undersides thereof, the decking system further comprising a shim with a pier-engagement surface and a stabilizer extending from the pier-engagement surface, wherein the pier-engagement surface of the shim receives one of the plurality of structural piers thereon, and wherein the stabilizer of the shim is received in the hollow cavity of the receiver blocks.
 17. The decking system of claim 16, wherein the shim is a first shim, and wherein the decking system further comprises a second shim having a stabilizer thereon, wherein the stabilizer of the first shim defines a hollow cavity on the underside thereof, and wherein the second shim receives the first shim thereon, the stabilizer of the second shim being received in the hollow cavity of the first shim.
 18. The decking system of claim 16, wherein the shim further comprises a plurality of structural ribs therein.
 19. The decking system of claim 9, wherein the upper surface of the surface pad further comprises a plurality of channels therein to provide drainage for the decking system.
 20. The decking system of claim 9, wherein the surface pad detachably engages with the generally dome-shaped load-bearing surface structural pier. 